Electrical Controls Engineer

Electrical Controls Engineer

The Electrical Controls Engineer designs, coordinates, and executes electrical and automation projects that support manufacturing operations across multiple facilities. This role leads electrical upgrades and new equipment installations, provides remote and onsite technical support, and identifies opportunities for automation, robotics, data collection, energy savings, and efficiency and safety improvements. The engineer ensures that all automated systems meet required functions and production needs while collaborating closely with manufacturing, maintenance, and production teams.

Responsibilities:

• Design, coordinate, and execute electrical and automation projects to support manufacturing operations across multiple facilities.
• Lead electrical upgrades and new equipment installations from concept through commissioning.
• Provide remote and onsite technical support to manufacturing facilities, including on-call plant support.
• Identify and implement automation opportunities, including robotics, data collection, energy savings, efficiency improvements, and safety enhancements.
• Work closely with Manufacturing Engineering, Machine Tool Operation, Plant Services, Plant Maintenance, and Production personnel to scope, develop, and install new and rebuilt systems.
• Collaborate with Production and Engineering teams to ensure all work meets the needs and expectations of key stakeholders.
• Design large electrical enclosures, sub-panel layouts, and wiring diagrams in alignment with UL/CUL/CSA certifications and NFPA 79 wiring standards.
• Review and critique electrical designs created by other engineers to ensure quality and compliance with standards.
• Perform Factory Acceptance Tests (FAT) on large electrical panels and electrical equipment to validate performance and safety.
• Work with project originators to ensure the scope of work is clearly defined and the sequence of operations is accurately captured.
• Maintain software, programs, drawings, and files, ensuring they remain current, accurate, and properly documented.
• Develop detailed electrical panel designs and conduct panel design reviews with the engineering team.
• Coordinate with Operations teams to schedule, plan, and implement equipment installations and equipment upgrades.
• Write PLC, HMI, drive, and related control programs for assigned projects, with expert-level PLC programming capability.
• Provide startup training on control systems that is clear and easily understood by production operators and plant maintenance personnel.
• Create complete and accurate bills of materials for electrical panels, control systems, and related projects.
• Travel within the United States and Canada, with anticipated travel of approximately 30–35%, including extended trips during the first six months.

Essential

Skills:

• 3–5 years of experience working with Rockwell (Allen-Bradley) PLCs.
• 3–5 years of experience in electrical panel design using AutoCAD Electrical, including designing panels from scratch.
• Expert-level PLC programming skills, particularly with Allen-Bradley PLCs and Studio 5000.
• Strong experience in electrical design of control panels and systems.
• Proficiency in HMI programming for industrial automation systems.
• Hands-on experience with Factory Acceptance Testing (FAT) of electrical panels and equipment.
• Ability to design electrical enclosures, sub-panel layouts, and wiring diagrams to UL/CUL/CSA and NFPA 79 standards.
• Strong troubleshooting skills in electrical, controls, and automation systems.
• Proficiency in reading and creating electrical schematics.
• Ability to maintain and manage software, programs, drawings, and technical files accurately.
• Willingness and ability to travel 30–35%, including 1–2 weeks per month with weekends at home, especially during the first six months.

Additional Skills &

Qualifications:

• Experience with Rockwell Automation platforms and tools.
• Background in controls engineering within a manufacturing or industrial environment.
• Experience collaborating with cross-functional teams such as production, maintenance, and engineering.
• Strong communication skills for providing clear training and documentation to operators and maintenance staff.
• Ability to…